I try my best to convey my own and friends experiences to try and save others the time $$ and grief that comes with trying to reinvent the wheel. We put lexan in my brother's race car (except windshield) so I knew the distortion issues and how easily even the new coated version scratches. I know from experience that the 56 cab is one of the most difficult to chop and be able to refit with glass. Even some of the "best" think it should be able to be done without splitting the roof i.e. West Coast Customs quickly switch to the 55 cab for Stalone's movie truck. Others who have been down the path and/or forsee the problems, either split the roof then refit the windshield frame to the cut in advance glass, slide the uncut glass up into a channel cut into the header, or leave the windshield, frame, and roof completely alone and take the "chop" out of the cowl metal below the windshield (technically a "sectioning" of the cowl, only the doors and rear of the cab are "chopped") ala Foose 56.
Those who have to find out the hard way do the chop without splitting the top and re- angle the posts either stubbornly spend a lot of time and money scratching their head while trying to make something work before reaching the ultimate conclusion they made a mistake and starting over or selling off their FUBARed cab/truck to some other "clueless sucker" (sorry, if the shoe fits...) who thinks he's getting the bargain of the century.
Nordvik, if you weren't so closed minded to anyone who s not telling you what you want to hear rather than the truth, you would realize I am a "do-er" with significant experience and knowlege. I am not going to lie and tell you everything will be all right. I really don't care if you don't believe me or my message, I am mostly interested in preventing others reading this from straying down the same very enticing road to end up on a dead end path. I really like Keith and highly admire his building skills, I feel very badly that even he sucumbed to straying onto the road of impossibility. I can only hope that soon he will stop beating his head against the wall and find a new cab to start over and do right. He's already invested more money and time than a do over would have required.

 

Well I'm still betting on Keith's being able to do it.

 

He may have to build the darn window opening bit by bit around the windshield but I'll bet he gets it done.

 

I think you hit the nail on the head bacagrizz.
Re-shaping the opening looks to be the only way.
I'll keep you posted

 

Unfortunately fitting the frame to a cut glass will require the roof to be widened. Cutting the sides of the windshield to narrow it at the top will open a whole new can of worms with trying to get the shape to look right and sucessfully cutting the glass.
Keith, if you are going to reshape the opening, I might suggest making it a flush (glue) mount instead of the rubber gasket. You can then clean up the appearance with the required black painted edge and it will be less likely to plague you with leakage problems. Flush mounting can be touted as an upgrade modification as well.

 

thanks ax but the opening needs to be narrower not wider
I cut it (the frame) tonight I'll post some pictures tomorrow.

 

I'm really glad I have Flat glass in my chop top. RUSTY

 

here are the pic's
the bottom rail need's to move in about a 1/4"
the top corner need's to move in about a 1/2"
picture of removed parts


new base with new radius / contour


new base and new rubber rail


this is where i'm at tonight i'll update when finished

 

SUBSCRIBED

You guys are totally amazing what you can to fabricate a solution!

Good work.

 

Lovin' it Keith -

 

Keith, You really should invest in a shrinker/stretcher, not that expensive and IMHO you'd get a lot of use out of it. Saves all that notching and welding, gives smooth curves. You could have curved those pieces very precisely in ~ 5 min. each, with most of the time spent checking the fit. It's one of those must have, how did I ever get along without it tool.

 

no, this page is blue... not tan. Sheesh! thought I was on the HAMB for a minute.
keep on keepin on Keith.
here's another rootin for ya
show that chop who's boss!
JML

 

Don't let it get you down Keith, I know you'll find a solution, you always do

We're pulling for ya

Bobby

 

If everyone just keeps it friendly - we can all enjoy.
Lets get back to the topic at hand, Keith's cool Crew Cab (I checked it out on the weekend just past - its pretty dang amazing - his attention to detail is )

 

By the way - I deleted some posts in this thread, I trust if you read our guidelines you will understand why, but if you have any questions please PM me.
https://www.ford-trucks.com/guidelines.html

Again - back to Keiths Crew Cab.